WeldHelp

MIG Filler Wire

2012-03-07T15:59:00.000-08:00

Low carbon or mild steel filler wire specifications are found in the CSA standard W48.8 and in the AWS standard A5.18.

CSA

ER 480S-6

E = Electrode

R = The wire can be used as filler rod for TIG welding

480 = 480 MPa tensile strength

S = Solid wire

6 = Deoxidizers and other additions in the wire

AWS

ER 70S-6

E = Electrode

R = The wire can be used as filler rod for TIG welding

70 = 70,000 psi tensile strength

S = Solid wire

6 = Deoxidizers and other additions in the wire

MIG Gases

2012-03-07T14:32:00.001-08:00

MIG Gases (Short Circuit Transfer)
Metal	Gas	Advantages
Carbon Steel	75% argon + 25% carbon dioxide	Less than 1/8” thick -High welding speed -No burn-through -Minimum distortion and spatter
	75% argon + 25% carbon dioxide	More than 1/8” thick -Minimum spatter -Clean weld appearance -Good puddle control in vertical and overhead positions -Both GMAW and FCAW
	carbon dioxide	-Deeper penetration -Faster welding speeds -Both GMAW and FCAW
Stainless Steel	90% helium + 7.5% argon + 2.5% carbon dioxide	-No effect on corrosion resistance -Small heat-affected zone -No undercut -Minimum distortion
Low Alloy Steel	60-70% helium + 25-35% argon + 4-5% carbon dioxide	-Minimum reactivity -Excellent toughness -Excellent arc stability, wetting characteristics and bead contour -Little spatter.
Low Alloy Steel	75% argon + 25% carbon dioxide	-Fair toughness -Excellent arc stability, wetting characteristics and bead contour -Little spatter
Aluminum, Copper, Magnesium, Nickel and their alloys	Argon & argon + helium	-Satisfactory on sheet metal -Argon-helium preferred on material over 1/8”

MIG Gases (Spray Transfer)
Metal	Gas	Advantages
Carbon Steel	Argon + 1-5% oxygen	-Improved arc stability -More fluid and controllable weld puddle -Good bead contour -Minimum undercut -Higher speeds than pure argon
Carbon Steel	Argon + 3-10% carbon dioxide	-Good bead shape -Minimum spatter -Reduced chance of cold lap -Flat/horizontal position only
Low Alloy Steel	Argon + 2% oxygen	-Minimum undercut -Good toughness
Aluminum	Argon	Up to 1" thick -Best metal transfer and arc stability -Least spatter
	35% argon + 65% helium	Up to 1" thick -Higher heat input than pure argon -Improved fusion characteristics with 5XXX series Al-Mg alloys
	25% argon + 75% helium	Over 3” thick -Highest heat input -Minimum porosity
Magnesium	Argon	-Excellent cleaning action
Stainless Steel	Argon + 1% oxygen	-Improved arc stability -More fluid and controllable weld puddle -Good bead contour -Minimum undercut on heavier stainless steels
Stainless Steel	Argon + 2% oxygen	-Better arc stability & welding speed than 1% oxygen mixture for thinner stainless steels
Copper, nickel and their alloys	Argon	-Good wetting characteristics -Decreased fluidity of weld metal for thickness' up to 1/8”
Copper, nickel and their alloys	Argon + helium	-Higher heat inputs to 50 and 75% helium mixtures offset high heat dissipation of heavier gauge materials
Titanium	Argon	-Good arc stability -Minimum weld contamination -Inert gas backing is required to prevent air contamination on back of weld

Mig Whip Size

2012-03-07T12:37:00.001-08:00

Whip Size
Amps	Max. Cable Length	Cable Size
200	15'	No. 1
300	15'	No. 2/0
400	15'	No. 3/0
500	15'	No. 4/0
600	15'	No. 2-2/0

MIG

2012-03-06T20:34:00.001-08:00

MIG welding (also known as GMAW or wire welding) is one of the most popular forms of welding. It is mainly used in high production projects where speed is a factor.

MIG = Metal Inert Gas

GMAW = Gas Metal Arc Welding

Always DC current. DCEP usually for steel and always for aluminum.

Often constant potential (CP/CV) machines used.

High deposition rate

92% - 98% filler metal forms weld deposit.

Concentrates more current at one point than SMAW arc, producing deeper penetration.

Less heat input per linear inch of weld.

Suited to welding low carbon structural steels, low alloy stainless steels and hardsurfacing.

Penetration is highest when doing globular transfer.

Spray transfer requires a minimum of 80% argon and only on DCEP.

Longer stickout = voltage increases/current decreases

Shorter stickout = voltage decreases/current increases

Inductance controls the rate of current rise.

Metal Melting Temperatures

2012-03-06T19:34:00.001-08:00

Metal	Melting Point
Metal	*(Celcius)*	*(Farenheit)*
Admiralty Brass	900 - 940	1650 - 1720
Aluminum	660	1220
Aluminum Bronze	600 - 655	1190 - 1215
Antimony	630	1170
Beryllium	1285	2345
Beryllium Copper	865 - 955	1587 - 1750
Bismuth	271.4	520.5
Brass	930	1710
Cadmium	321	610
Cast Iron, gray	1175 - 1290	2150 - 2360
Chromium	1860	3380
Cobalt	1495	2723
Copper	1084	1983
Cupronickel	1170 - 1240	2140 - 2260
Gold	1063	1945
Hastelloy C	1320 - 1350	2410 - 2460
Inconel	1390 - 1425	2540 - 2600
Incoloy	1390 - 1425	2540 - 2600
Iridium	2450	4440
Iron	1536	2797
Lead	327.5	621
Magnesium	650	1200
Manganese	1244	2271
Manganese bronze	865 - 890	1590 - 1630
Mercury	-38.86	-37.95
Molybdenum	2620	4750
Monel	1300 - 1350	2370 - 2460
Nickel	1453	2647
Niobium (Columbium)	2470	4473
Osmium	3025	5477
Platinum	1770	3220
Plutonium	640	1180
Potassium	63.3	146
Red Brass	990 - 1025	1810 - 1880
Rhodium	1965	3569
Selenium	217	423
Silicon	1411	2572
Silver	961	1760
Sodium	97.83	208
Carbon Steel	1425 - 1540	2600 - 2800
Stainless Steel	1510	2750
Tantalum	2980	5400
Thorium	1750	3180
Tin	232	449.4
Titanium	1670	3040
Tungsten	3400	6150
Uranium	1132	2070
Vanadium	1900	3450
Yellow Brass	905 - 932	1660 - 1710
Zinc	419.5	787
Zirconium	1854	3369

MIG like TIG

2012-03-06T12:59:00.002-08:00

Everyone wants to make their welds look like TIG welds these days. To do so you don't really have to do much. If you just step forward, then pause and let your puddle fill in you will get the general profile of a TIG weld. Just practice with your rate of travel and pause length and you will have it in no time.
This is my attempt:

TIG

2012-03-06T12:54:00.002-08:00

TIG welding may be one of the more difficult welding processes to learn but once you get it down it just looks and feels like you should have been doing it all along.

Here's some tips to get you started:

TIG = Tungsten Inert Gas

GTAW = Gas Tungsten Arc Welding

Tungsten Melting Temp.=3375ºC (6100ºF)

Water cooled torch for amperage’s over 150 A

TIG machines must produce a constant current (CC)

Mild and stainless steel = DCEN (approx. 2/3^rds of heat in workpiece, 1/3^rd of heat in electrode)

Aluminum = AC or ACHF (Greater current during the DCEN half cycle and a reduced DCEP half cycle)

Water Cooling Pressure = Around 35 psi (245 kPa), approx. 1L per minute.

Pulsed Current used for thinner materials and for vertical and overhead positions.

TIG Table

2012-03-06T12:48:00.002-08:00

Material	AC	DC
Material	With HF	Straight Polarity (EN)	Reverse Polarity (EP)
Aluminum up to 3/32” thick Aluminum over 3/32” thick Aluminum Castings Brass Alloys Cast Iron Deoxidized Copper Hard-Facing Hastelloy Alloys High Carbon Steel Low Carbon Steel Magnesium up to 1/8” thick Magnesium over 1/8” thick Magnesium Castings Stainless Steel Silicon Copper Silver Silver Cladding	Excellent Excellent Excellent Good Good Not Recommended Excellent Good Good Good Excellent Excellent Excellent Good Not Recommended Good Excellent	Not Recommended Not Recommended Not Recommended Excellent Excellent Excellent Excellent Excellent Excellent Excellent Not Recommended Not Recommended Not Recommended Excellent Excellent Excellent Not Recommended	Good Not Recommended Not Recommended Not Recommended Not Recommended Not Recommended Not Recommended Not Recommended Not Recommended Not Recommended Good Not Recommended Good Not Recommended Not Recommended Not Recommended Not Recommended

Learn to MIG on a 110A machine

2012-02-28T18:21:00.000-08:00

Here's a video for newbie mig welders. It shows you pretty much everything you need to know to start migging.

Miller - Welding Calculators

2012-02-28T13:23:00.000-08:00

Miller - Welding Calculators

Glossary

2012-02-28T12:47:00.002-08:00

Throughout the course of my blogging career I will be adding more and more to this glossary so if you have any ideas please feel free to comment and I will add them.

AC = Alternating Current

Amps = The measurement of the electrical (current) flow.

Arc Blow = A magnetic field that deflects the arc to one side caused by a DC circuit.

AWS = American Welding Society

CFH = Cubic Feet per Hour

CGA = Compressed Gas Association

CSA = Canadian Standards Association

CWB = Canadian Welding Bureau

Constant Current (CC) = a machine that varies its output voltage to maintain a steady current.

Constant Potential/Voltage (CP/CV) = a machine that will fluctuate its output current to maintain a set voltage.

DCEN = Direct Current Electrode Negative

DCEP = Direct Current Electrode Positive (Creates a cleaning action with TIG)

Down Slope = The control of the ending amperage at the moment the arc is extinguished opposed to the set amperage for welding.

GMAW = Gas Metal Arc Welding

GTAW = Gas Tungsten Arc Welding

High Frequency (HF) = The ionization of gas between the electrode and workpiece creating an arc.

Inductance = The rate of current rise.

Inert Gas = A gas that has little or no ability to react chemically.

L/min = Litres per minute.

MIG = Metal Inert Gas

Ohm = The measurement of resistance in an electrical conductor.

Ohm's Law = E = I x R (Voltage=Current in amps x Resistance in ohms)

Pre-Purge (Pre-Flow) = The flow of gas before the arc is struck.

Post-Purge (Post-Flow) = The flow of gas after the arc is extinguished.

Resistance = The force that prevents the flow of electricity. (Wire size, electrical conductors, etc.)

Reverse Polarity = DCEP

SAW = Submerged Arc Welding

Single-Phase = An AC current different in phase by 180º

SMAW = Shielded Metal Arc Welding

Stick Welding = Sometimes called Arc welding. With a flux coated stick electrode.

Straight Polarity = DCEN

Three-Phase = An AC current with 3 single-phase currents timed to start at regular intervals from each other.

TIG = Tungsten Inert Gas

Up Slope = The control of the starting amperage at the moment the arc is ignited opposed to the set amperage for welding.

Volts = Electrical pressure

Sick of seeing improper and unsafe welding procedures.

2012-02-28T11:49:00.002-08:00

I watch a fair amount of TV and the majority of what I watch is shows that contain welding. Sometimes I find them hard to watch because of not only the terrible welds but also because of the lack of safety gear and sheer stupidity. I'm watching TV right now and they hired a new girl welder. I'm not saying there's anything wrong with girl welders but why would you weld without gloves and without a mask on? I also just saw them MIG welding aluminum downhand.

Tell me what you think!

2012-02-28T10:44:00.002-08:00

This is a blog for all the welders and fabricators out there. Whether you need some help with something or are just curious about the metal trades, this is the place to be. For the welding portion of this blog I will be talking about everything from proper structural techniques to just simply making a weld look nice. I will also be talking about metallurgy, fabrication, safety.. etc.